Attention: Before installing additional devices that consume electricity, it is necessary to check whether the existing alternator can handle the increased load. If necessary, install a high power generator.
Checking the alternator charging voltage
If the battery is not sufficiently charged, the alternator charging voltage must be checked.
Connect a voltmeter between the positive and negative poles of the battery.
Start the engine. When starting the engine, the voltage with a fully charged battery should not fall below 8 volts (at an electrolyte temperature of approximately +20°С).
Increase the engine speed to 3000 rpm. In this case, the voltage should be from 13.0 to 14.5 volts. This is proof that the generator and relay-regulator are working properly. To recharge the battery while driving, the alternator voltage (onboard voltage) must be higher than the battery voltage.
Check the stability of the voltage regulation. To do this, turn on the main beam and repeat the measurement at an engine speed of 3000 rpm. The measured voltage value should not exceed the previously obtained value by more than 0.4 volts.
If the measured voltage values are out of range, the generator and the relay-regulator must be checked at the service station.
Safety instructions
When working on the electrical system, be sure to disconnect the ground wire from the battery (-).
Attention: This erases the contents of electronic memory devices, such as engine trouble codes. Before disconnecting the battery, you must also read the instructions in chapter «Removing and installing the battery».
I Do not disconnect the battery or voltage regulator while the engine is running.
Do not remove the alternator with the battery connected.
Before carrying out electric welding work, the battery must be disconnected.
Removing
With the ignition off, disconnect the ground wire from the battery (-).
Attention: Follow the instructions given in chapter «Removing and installing the battery».
Note: depending on the model, generators of different designs are installed.
Generator 1
1 - Phillips head screws
2 - protective cover
3 - nut
4 - nut
5 - Phillips head screws
6 - voltage regulator
7 - generator
8 - bolts, 25 Nm
9 - V-ribbed belt
Generator 2
1 - Phillips head screws
2 - protective cover
3 - nut
4 - nut
5 - Phillips head screws
6 - voltage regulator
7 - generator
8 - bolts, 25 Nm
9 - V-ribbed belt
Loosen poly V-belt -9- and remove.
Disconnect the plug connector on the rear side of the generator and unscrew the fastening of the thin wire (D+).
Remove the protective cap and unscrew the fastening of the thick wire (B+).
Remove bolts -8- and remove alternator from crankcase.
Installation
Attach the generator and bolt it to the bracket.
Check poly V-belt for wear and replace if necessary.
Place the V-ribbed belt on the pulleys and tighten.
Attach wire to generator (B+). The tightening torque is 15 Nm.
Attention: If the wire fastening is tightened with a torque that does not correspond to the prescribed value, the following malfunctions may occur:
- The battery is not fully charged.
- Complete failure of automotive electrical / electronics.
- Fire hazard due to sparks.
- Damage due to overvoltage of electronic parts/control units.
Screw a thin wire to the generator (D+).
With the ignition off, connect the ground wire (-) to the battery.
Attention: Follow the instructions given in chapter «Removing and installing the battery».
After installation, start the engine and check the running of the V-ribbed belt.
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